Non-woven structures and methods of making the same

ABSTRACT

anchoring layer, including patterned and non-patterned structures. Also provided are personal care products comprising the present structures and methods of making the structures.

FIELD OF THE INVENTION

The present invention relates generally to layered, composite materials.More specifically, the present invention relates to layered, compositematerials exhibiting advantageous lamination strength, and one or moreadditional beneficial properties such as drapeability, loftiness,abrasion resistance, liquid absorbency, softness, and/or visual appeal.

BACKGROUND

Non-woven materials are used widely in a variety ofcommercially-available personal care products including, for example,wipes and feminine hygiene products, such as napkins, liners, andtampons, and the like. In many of these applications, it is desirablefor the non-woven materials to have sufficient strength such that thematerial maintains its integrity in use. For example, it is oftendesirable in certain uses to reduce delamination that might otherwiseoccur between various material layers of the nonwoven.

Applicants have further recognized that it is also desirable for suchmaterials to have other beneficial properties in combination withrelatively high strength/integrity. For example, it would be desirableto have such materials that are abrasion resistant and/or also“drapeable” so as to provide comfort to the user. As used herein, theterm “drapeable” refers to the tendency of a material to hang in asubstantially vertical fashion due to gravity when held in acantilevered manner from one end of the material. Materials exhibitinghigh drapeability tend to conform to the shape of an abutting surface,such as against a user's skin, thereby tending to enhance comfort to theuser of a product comprising the high-drape material. Applicants havefurther recognized that it is also desirable in certain applications forthe relatively strong nonwovens to be bulky (i.e., low density), and/orto have patterns therein.

Accordingly, applicants have recognized the need for non-woven materialsthat exhibit the highly desirable, and unique combination of highlamination strength/high-integrity and either or both of highdrapeability properties or low density, for use in any of a variety ofarticles. In addition, applicants have recognized the need for uniquemethods of producing such materials, including, but not necessarilylimited to, methods of producing such materials via thehydroentanglement of nonwovens and novel patterning methods.

SUMMARY OF INVENTION

Applicants have met the need identified above by producing a fibrous,composite structure having the unique and desirable combination ofrelatively high lamination strength in combination with highdrapeability and/or low density properties.

According to one aspect, the present invention is directed to a layered,composite material comprising a fibrous, fluid-permeable anchoring layerand a fibrous layer comprising fibers entangled about said anchoringlayer, said composite material having a lamination strength of greaterthan about 20 grams and a drapeability of greater than about 4 gsm/g

According to another aspect, the present invention is directed alayered, composite material comprising a fibrous, fluid-permeableanchoring layer and a fibrous layer comprising fibers entangled aboutsaid anchoring layer, said composite material having a laminationstrength of greater than about 20 grams and a density less than about0.15 grams per cubic centimeter (g/cc).

The composite materials of the present invention may be used to greatbenefit in a wide variety of personal care articles. Accordingly, inanother embodiment, the present invention is directed to a personal carearticle comprising a composite material of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of embodiments of the present invention will now be describedwith reference to the drawings, in which:

FIG. 1 is a cross-sectional view of an embodiment of a layered,composite material of the invention described herein;

FIG. 2 is a cross-sectional view of another embodiment of a layered,composite material of the invention described herein;

FIG. 3 is a top, plan view of another embodiment of a layered, compositematerial of the invention described herein, showing additional featuresthereof;

FIG. 4 is a cross-sectional view of the layered, composite material ofFIG. 3, taken through line 3-3′;

FIG. 5 is a cross-sectional view depicting the formation of a layered,composite material according to a process consistent with embodiments ofthe invention described herein;

FIG. 6 is a cross-sectional view depicting the formation of a layered,composite material according to another process consistent withembodiments of the invention described herein;

FIG. 7 is a perspective view of a mask that may be used to form alayered composite material consistent with embodiments of the inventiondescribed herein;

FIG. 8 is a plan view of a length of patterned, layered compositematerial 810 consistent with embodiments of the invention describedherein; and

FIG. 9 is a cross-sectional view depicting the patterning of a layered,composite material according to embodiments of the invention describedherein.

DESCRIPTION OF PREFERRED EMBODIMENTS

According to certain embodiments, the present invention is directed tolayered, composite materials comprising a fibrous, fluid permeableanchoring layer and a fibrous layer having fibers entangled about theanchoring layer, which composite materials exhibit a unique combinationof relatively high lamination strength in conjunction in one or morerelatively high drapeability, and/or low density (high bulkiness or“bulk”) as compared to conventional non-woven structures. Such uniquematerials are, in certain embodiments, also beneficially abrasionresistant, durable, soft, comfortable, and/or absorbent. In certainembodiments, such materials are further useful for providing variousother benefits, including fluid absorption or fluid isolation,cleansing, and exfoliation capability in a variety of products.

In particular, applicants have measured the lamination strength ofcomposite materials according to certain embodiments of the presentinvention in accord with the “Lamination Strength Test” described indetail below. As will be understood by those of skill in the art, aresulting higher Lamination Strength Value indicates a relativelygreater ability for the anchoring layer and fibrous layer having fibersentangled about the anchoring layer of the composite material to resistde-bonding from one another as a result of applied force and a lowerLamination Strength Value indicates a relatively lesser ability for thetwo layers to resist de-bonding upon applied force. In addition,applicants have recognized that a relatively high lamination strengthtends to correlate to the consumer-desirable “durability” of thelayered, composite material. According to certain embodiments, thepresent composite material exhibit a Lamination Strength Value that isabout 20 grams or more, more preferably about 50 grams or more, and evenmore preferably from about 100 grams or more.

Applicants have also measured the drapeablility of the presentstructures via the “Drapeability Test”, described in detail below andunderstood by those of skill in the art. Applicants have recognized thatin certain embodiments the present structures exhibit not only desirablyhigh lamination strength, as described above, but also exhibitrelatively high drapeability in combination therewith. In particular,according to certain embodiments, the present structures exhibit adrapeability (basis weight/MCB) that is greater than about 4 grams persquare meter per gram (gsm/g) or greater, preferably greater than about6 gsm/g, and even more preferably from about 8 gsm/g to about 16 gsm/g.

Applicants have also measured the density of the composite materials ofcertain preferred embodiments of the present invention via the “DensityTest,” described in detail below and understood by those of skill in theart. Applicants have recognized that in certain embodiments the presentstructures exhibit not only desirably high lamination strength, asdescribed above, but also exhibit relatively low density in combinationtherewith. According to certain embodiments, the present structuresexhibit a density that is about 0.15 g/cc or less, more preferably about0.12 g/cc or less, and even more preferably from about 0.12 g/cc toabout 0.03 g/cc.

According to certain embodiments, applicants have recognized that inaddition to relatively high lamination strength in combination withrelatively high drapeability and/or relatively low density, thecomposite materials of the present invention further comprise one ormore properties selected from relatively high absorbent capacity,relatively high tensile strength, desirable thickness, and combinationsof two or more thereof. For example, in certain embodiments of theinvention, the layered, composite material has an absorbent capacitythat is greater than about 3 g/g, preferably greater than about 4 g/g,and more preferably about 5 g/g. In certain embodiments, the compositematerial has a tensile strength in the machine direction (measured viathe “Tensile Strength Test,” described in detail below and understood bythose of skill in the art) of about 10 N/5 cm or more, preferably about15 N/5 cm or more, more preferably about 20 N/5 cm or more. Thethickness of the composite materials of the present invention may beoptimized for use in any of a wide range of articles and anysuitable/desired thickness for a particular article may be used. Incertain preferred embodiments, the composite materials of the presentinvention have a thickness of less than about 10 mm, preferably lessthan about 5 mm, more preferably less than about 2 mm, and even morepreferably from about 0.3 mm to about 2 mm.

FIG. 1 is a cross-sectional view depicting an embodiment of a layered,composite material 100 consistent with embodiments of the inventiondescribed herein. The layered, composite material 100 comprises afibrous, fluid-permeable anchoring layer 110 and a fibrous layer 122having fibers 120, at least a portion of which are entangled aboutanchoring layer 110.

The fluid-permeable, anchoring layer 110 may comprise any suitablefibrous material that is permeable to fluids. By permeable to fluids, itis meant that gases or liquids, such as water (and the like) may beurged through a cross-section of the fluid-permeable, anchoring layer110, i.e, from an outer surface 112 of the fluid-permeable, anchoringlayer 110, through the fluid-permeable, anchoring layer 110 to emergefrom an inner surface 114 of the fluid-permeable, anchoring layer 110.In certain preferred embodiments, to facilitate the movement of fluidthrough the fluid-permeable, anchoring layer 110, the fluid-permeable,anchoring layer 110 comprises a network of interconnected pores 116. Incertain preferred embodiments, the anchoring layer has a percent openarea of about 25% or more. Preferably, the fluid-permable, anchoringlayer 110 is also generally resistant to dissolution and mechanicaldegradation that would be caused by urging high pressure fluids such aswater or air therethrough.

In certain embodiments, the fluid-permeable, anchoring layer 110 isrelatively thin, for example, having thickness of less than about 2000microns, more preferably from about 3 to about 2000 microns. Thefluid-permeable, anchoring layer 110 may be of any suitable basisweight. In certain preferred embodiments, the anchoring layer has abasis weight of from about 5 gsm to about 20 gsm, and more preferably,about 5 gsm to about 15 gsm. Furthermore, the fluid-permeable, anchoringlayer 110 is preferably mechanically integrated such that it has atensile strength of at least about 5 N/5 cm. Additionally, it isdesirable that the fluid-permeable anchoring layer is preferablyselected to be relatively flexible (i.e. tends not to be stiff) whichapplicants have recognized tends to benefit in the drapeabilityassociated with a material incorporating the anchoring layer.

In preferred embodiments, the fluid-permeable, anchoring layer 110comprises or consists essentially of a polymeric material, such as abonded, fibrous material, including a spun-bond or thermobonded, such asa through-air bonded, material, and the like. By “through air bond,” itis meant fibers that have been oriented by various means such as cardingand have been bonded together by passing a heated stream of airtherethrough. By “spun bond” it is meant fibers that are melt spun byextruding molten thermoplastic polymer as fibers from a plurality offine, usually circular, capillaries of a spinneret with the diameter ofthe extruded fibers then being rapidly reduced by drawing and thenquenching the fibers. Spun-bond fibers are usually continuous fibers.Suitable spun-bonded materials are formed from fibers having a diameterfrom about 3 microns to about 20 microns and having a fiber lengthgreater than about 200 mm. The fibers of the anchoring layer may includesuch materials as polyolefins such as polypropylene, polyethylene,bicomponent fibers formed from polypropylene, polyethylene, orcombinations thereof. The spun bond fibers may be subsequentlycompressed to provide increased strength or reduced thickness. In apreferred embodiment, the fluid-permeable, anchoring layer 110 comprisesor consists essentially of a spun bond material.

The outer surface 112 of the fluid-permeable, anchoring layer 110 isgenerally an abrasion resistant surface. By “abrasion resistant” it ismeant that the outer surface 112 generally resists degradation fromresilient objects, e.g., a hand or other body surfaces being passedacross the outer surface 112.

The layered, composite material 100 comprises fibers 120 at least aportion of which are entangled about the fluid-permeable, anchoringlayer 110. The fibers are preferably associated with a fibrous layer122. The fibers entangled about the fluid-permeable, anchoring layer 110preferably includes a plurality of fibers or filaments that areassociated with one another and with the fluid-permeable, anchoringlayer 110 such as by entanglement. As such, the fluid-permeable,anchoring layer 110 in effect serves as a “skeleton” for the layered,composite material 100.

The entanglement of the fibers about the fluid-permeable, anchoringlayer 110 generally results in a bonding between the fibrous layer 122and the fluid-permeable, anchoring layer 110 about an interface 124.While the interface 124 is depicted essentially a line in FIG. 1, theinterface 124 generally has a thickness associated therewith. The natureof the interface 124 is that of fibers twisted, knotted, tied orotherwise entangled about the fluid-permeable, anchoring layer 110.

In certain preferred embodiments, the anchoring layer 110 and the fibersof the fibrous layer 122 entangled about the anchoring layer 110 aresubstantially free of bonding formed from melting the fibers and/oranchoring layer 110 and/or bonding formed using chemical adhesives. Asused herein the term “substantially free of bonding formed from meltingthe fibers and/or anchoring layer 110 and/or bonding formed usingchemical adhesives” means a material wherein less than 10% by weight ofthe fibers of fibrous layer 122 bonded to anchoring layer 110 are sobonded via melting or chemical adhesives. Preferably, a materialsubstantially free of bonding formed from melting the fibers and/oranchoring layer 110 and/or bonding formed using chemical adhesivescomprises less than 5%, and more preferably no fibers of fibrous layer112, that are bonded to the anchoring layer 110 via melting or chemicaladhesives. While applicants do not wish to be bound by or to any theoryof operation, it is believed that by restricting the bonding of thefibers of the fibrous layer 122 and the fluid-permeable, anchoring layer110 to physical entanglement rather than melt bonding or chemicaladhesives, the resulting layered, composite material 100 tends to bemore drapeable.

Any of a wide variety of various fibers may be selected for use in thefibrous layer 122. Examples of suitable fibers include those derivedfrom cellulose, polyester, rayon, polyolefin, polyvinyl alcohol,polyamide or other synthetic fibers, combinations of two or morethereof, and the like. Certain preferred fibers include cellulose,polyester, rayon, or polyolefin, alone or in combinations of two or morethereof. Examples of commercially available suitable fibers include“Galaxy” rayon fibers commercially available from Kelheim Fibers,Kelheim, Germany or Tencel lyocell fibers commercially available fromLenzing AG of Lenzing, Austria.

In certain embodiments of the invention, the fibers include cellulosesuch as, for example, wood pulp. In one embodiment of the invention, thefibrous layer 122 includes from about 0% to about 100% pulp, morepreferably from about 5% to about 50%.

In certain preferred embodiments of the invention the wood pulp has areduced capacity for hydrogen bonding. Wood pulp having reduced capacityfor hydrogen bonding may be formed by a process that includes the stepof treating a liquid suspension of pulp at a temperature of from 15° C.to about 60° C. with an aqueous alkali metal salt solution having analkali metal salt concentration of from about 2 weight percent to about25 weight percent of said solution for a period of time ranging fromabout 5 minutes to about 60 minutes. Reagents suitable for caustictreatment include, but are not limited to, alkali metal hydroxides, suchas sodium hydroxide, potassium hydroxide, calcium hydroxide, andrubidium hydroxide, lithium hydroxides, and benzyltrimethylammoniumhydroxides. Sodium hydroxide is a particularly preferred reagent for usein the caustic treatment to produce cellulosic fibers suitable forforming the superabsorbent cellulosic fibers in accordance with thepresent invention. The pulp preferably is treated with an aqueoussolution containing from about 4 to about 30% by weight sodiumhydroxide, (or any other suitable caustic material), more preferablyfrom about 6 to about 20%, and most preferably from about 12 to about16% by weight, based on the weight of the solution. Caustic treatmentmay be performed during or after bleaching, purification, and drying.Preferably, the caustic treatment is carried out during the bleachingand/or drying process. Pulp so produced is sometimes referred to as“caustic extractive pulp” or “mercerized pulp.” Commercially availablecaustic extractive pulp suitable for use in the present inventioninclude, for example, Porosanier-J-HP, available from RayonierPerformance Fibers Division (Jesup, Ga.), Buckeye's HPZ,-available fromBuckeye Technologies (Perry, Fla.), and TRUCELL available fromWeyerhaeuser company (Federal Way, Wash.).

In another preferred embodiment of the invention, the pulp havingreduced capacity for hydrogen bonding is crosslinked. By “crosslinked”,refers to cellulosic fibers that have primarily intrafiber chemicalcrosslink bonds. That is, the crosslink bonds are primarily betweencellulose molecules of a single fiber, rather than between cellulosemolecules of separate fibers.

The crosslinked fibers may be formed by various processes, such as, (1)the process described in U.S. Pat. No. 3,241,553, issued to F. H.Steiger on Mar. 22, 1966, in which individualized, crosslinked fibersare produced by crosslinking the fibers in an aqueous solutioncontaining a crosslinking agent and a catalyst; or (2) the processdescribed in U.S. Pat. No. 3,224,926 issued to L. J. Bernardin on Dec.21, 1965, in which individualized, crosslinked fibers are produced byimpregnating swollen fibers in an aqueous solution with crosslinkingagent, dewatering and defiberizing the fibers by mechanical action, anddrying the fibers at elevated temperature to effect crosslinking whilethe fibers are in a substantially individual state; among other knownmethods. Commercially available crosslinked pulp suitable for use in thepresent invention include, for example, Columbus Modified Fiber, grade#CHB416, available from Weyerhauser Corporation, (Federal Way, Wash.).

In certain embodiments, the layered, composite material 100 ispreferably substantially free of fibers that are woven, knitted, tuftedor stitch-bonding, i.e., the layered, composite material preferablyincludes fibrous materials that are made directly from fiber rather thanyarn.

In addition to fibers, the fibrous layer 122 may comprise variousadditional materials well known in the art of the art of the manufactureof non-wovens for use in absorbent articles. For example, the fibrouslayer 122 may comprise polymers or other chemical fiber-finishes orparticulate materials such as superabsorbents which may be distributedamong the fibers used to enhance fluid absorption properties or pigmentsor other light-reflecting agents to promote a particular appearance. Thefibrous layer 122 is preferably substantially free of chemical bindersthat may otherwise increase stiffness or reduce the drapeability of thecomposite.

The fibrous layer 122 may be homogeneous or heterogeneous in terms offiber composition, throughout its thickness. In certain preferredembodiments, the fibrous layer 122 comprises a heterogenous mixture, forexample, comprising cellulose and synthetic fibers. In certain otherpreferred embodiments, fibrous layer 122 is a homogenous layer, forexample, consisting essentially of cellulose fibers or essentially ofsynthetic fibers.

In certain preferred embodiments of the invention, 50% by weight or moreof the fibers of the fibrous layer 122 are made of fibers having alength to diameter ratio greater than about 300. While such fibers maybe staple fibers or continuous filaments, it is preferred that thefibers are staple fibers. The fibers may be, for example, cellulosefibers such as wood pulp or cotton; synthetic fibers such as polyester,rayon, polyolefin, polyvinyl alcohol, multi-component (core-sheath)fibers and combinations of two or more thereof. The fibers may be may beplaced in association with one another using and suitable methodsincluding those described in detail below.

The fibrous layer of the present invention may be of any suitable basisweight. In certain preferred embodiments, the fibrous layer 122 may havea basis weight from about 20 gsm to about 200 gsm, preferably from about20 gsm to about 150 gsm.

In an alternative embodiment, as depicted in FIG. 2, the fibrous layer122 may itself comprise of a plurality of layers or strata. FIG. 2depicts an uppermost fibrous layer 210 and a lower fibrous layer 220. Inone embodiment, the uppermost fibrous layer 210 comprises of consistsessentially of one or more synthetic fibers such as olefinic orpolyester or bicomponent fibers; and the lower fibrous layer 220comprises or consists essentially of cellulose fibers. Furthermore,while FIG. 2 depicts fibrous layer 122 consisting of only 2 layers,additional layers having various compositions are contemplated.

In addition, while FIGS. 1 and 2 depict a single fluid-permeable,anchoring layer 110 one terminal end of the layered, composite material100, it is within the scope of the invention to include a secondfluid-permeable, anchoring layer 110 at an opposite terminal end of thelayered, composite material 100, thereby creating a “sandwich”structure, by which one or more fibrous layers are, en masse, sandwichedbetween the two fluid permeable anchoring layers. In such aconfiguration, two separate abrasion resistant surfaces are present.

One may tailor the properties of the layered, composite materials basedupon the desired properties. For example, generally to provide lowerdensity and higher drapeability one may choose, for example primarilypolyester, rayon, and blends thereof. If one were interested inproviding high absorbent capacity and lower cost, one may selectprimarily wood pulp. In order to balance all of these properties, thefibrous layer 122 may itself comprise separate layers of thesematerials.

In certain embodiments of the invention, the layered, composite materialis provided with a visible pattern. FIG. 3 is a top plan view of alayered, composite material consistent with embodiments of the inventiondescribed herein. The layered, composite material 100 includes discreteraised regions 300 surrounded by a matrix 310 of low regions. FIG. 4 isa cross section of FIG. 3 taken through section 3-3′, revealing variousfeatures thereof. The raised regions 300 and the lower regions 310 arevisibly distinct from one another, e.g., a viewer of average and unaidedeyesight should be able readily to discern the difference or contrastbetween the raised regions and the lower regions 310 when viewing thelayered, composite material 100 from a distance of 12 inches. In oneembodiment of the invention, the raised regions 300 preferably have aheight 320 that is from about 0.1 mm to about 5 mm, more preferably fromabout 0.5 mm to about 2 mm, and a length or width of at least about 0.5mm, more preferably at least about 1 mm, and most preferably at leastabout 3 mm.

In one embodiment of the invention, the raised regions 300 areunentangled and unbonded, i.e., no significant bonding is evident at aninterface 330 between the fluid-permeable, anchoring layer 110 and thefibrous layer 122 in the raised region 300. In this embodiment of theinvention, substantial bonding between the fluid-permeable, anchoringlayer 110 and the fibrous layer 122 exists only within the lower regions310, such as along interface 340. As such, cross sections of entangledregions 360 and cross sections of unentangled regions 350 (theboundaries of which are shown in phantom in FIG. 4) are present withinthe layered, composite material 100.

FIG. 4 depicts the layered, composite material 100 having a continuouscross-section (matrix) of entangled region 360 and a plurality ofdiscrete cross-sections of unenetangled regions 350 positionedsubstantially within the continuous cross-section of the entangledregion. This configuration is often desirable to provide sufficienttensile strength to the layered, composite material 100. However, otherconfigurations of raised regions and lower regions are alsocontemplated. For example, the raised regions may be arranged along anentire width or length of the layered, composite material 100 ratherthan be arranged as discrete regions 350 surrounded by or substantiallywithin the lower regions 360. Furthermore, the sense of the entangledregions and unentangled regions may be “inverted” as compared to thematerial shown in FIG. 3, e.g., the entangled regions may be positionedsubstantially within the unentangled regions.

In certain preferred embodiments, the layered, composite materials ofthe present invention are spun-lace structures. That is, they arematerials derived from a hydroentanglement or “spun-lace” process,preferably such processes as are described herein. Applicants have foundthat the structures of the present invention exhibit excellent abrasionresistance and surprisingly good lamination strength and/ordrapeability, and/ or density as compared to conventional fibrous,non-woven structures, especially conventional spun-lace materials. Suchnovel and surprising combination of properties provides significantadvantage to the instant structures in a variety of uses including, butnot limited to, personal care articles such as feminine hygiene productsand wipes.

In one embodiment of the invention, the layered, composite material isused as a component of a sanitary pad such as a sanitary napkin orpantiliner. For example, the layered, composite material may be atopsheet or an integrated topsheet/absorbent core layer of a pantilineror sanitary napkin.

In certain preferred embodiments, the layered, composite material issuch that the fluid-permeable, anchoring layer 110 is capable of beingoriented towards the body of a user, and thus the fluid-permeable,anchoring layer 110 is part of a body-faceable surface of the sanitarypad. In certain preferred embodiments, the layered, composite materialserves as an integrated topsheet/absorbent core layer of a sanitarynapkin or pantiliner. Such an integrated topsheet/absorbent core layercomprising a layered, composite material of the present invention wouldbe advantageous in that the integrated cover provides enhanced abrasionresistance, softness, absorbency, and drapeability, all of whichcontribute to enhancing comfort of the wearer.

In one embodiment of the invention, the fibrous, non-woven material isused as a component of a wipe, e.g., a “baby wipe,” a personalcare/cosmetic wipe or wipe (wet or dry) useful for personal cleansing,or a wipe for the cleansing of inanimate surfaces. Layered, compositematerials of the present invention may be used a single layer wipe or asone or more layers in a multi-layered wipe. Preferably, the abrasionresistant surface(s) of the layered, composite materials are positionedon the external surface(s) of the wipe so as to contact the users skin.A wipe material comprising a layered, composite materials of the presentinvention would be advantageous in that the wipe has both good abrasionresistance (and therefore durability) as well as softness,compressibility and absorbency.

METHODS OF THE PRESENT INVENTION

Layered, composite materials of the present invention may be producedvia any of a variety of novel methods discovered by applicants. Forexample, according to certain embodiments, the structures may beproduced via a method including urging a stream of fluid into contactwith a layered structure, wherein the layered structure includes fibersand a fluid-permeable, anchoring layer, wherein the fluid-permeable,anchoring layer is positioned to at least partially shield the layer offibers from the stream of fluid.

FIG. 5 illustrates one embodiment of a method of conducting ahydroentangling step according to the present invention. Thehydroentangling step comprises providing a layer of fibers 520, which islaid onto a screen 590 (e.g. a metal or plastic screen), which in turnrests upon a movable conveyer (not shown). The term “layer” it is meantan assembly of fibers that has a thickness that is substantially less indimension as compared with both a length and a width 205 of saidassembly. For example, the layer 520 may have a thickness that is lessthan about 10% of the width such as less than about 2% of the width. Ina preferred embodiment, the thin layer 200 of fibers is substantiallyplanar and less than about 20 mm in thickness, preferably less thanabout 5 mm. The thin layer of fibers has a composition and properties asdescribed above with reference to fibrous layer 122 described above anddepicted in FIGS. 1 and 2.

The layer of fibers 520 may be unbonded to one another. By “unbonded,”it is meant that the fibers in the thin layer 520 are loosely associatedwith one another, and the layer has a very low tensile strength, such asless than about 5 N/5 cm. In an alternative embodiment, the layer offibers 520 are bonded to one another, e.g. loosely bonded, prior tospun-lacing.

Fluid-permeable, anchoring layer 110 is positioned atop the layer offibers 520. The layer of fibers 520 and the fluid-permeable, anchoringlayer 110 thereby form a target web 550 to be entangled. In operation,the target web 550 is moved in a machine direction within the range ofjets 530 from which a stream of fluid 508, preferably a liquid, morepreferably water, is urged. It is contemplated that the layer of fibers520 may impact the target 550 in any suitable direction and with anypressure suitable to form a stabilized web. Preferably, the stream offluid 508 are oriented to impact the layer in a substantiallyperpendicular manner and at a pressure of for example from about 500 psito about 5000 psi. As used herein, the term “substantiallyperpendicular” (such as from about 20 degrees to about 0 degrees,preferably from about 10 to about 0 degrees, and more preferably fromabout 5 to about 0 degrees, and most preferably about 0 degrees).

The target web 550 may be moved in the machine direction before, during,and/or after contact with the stream of fluid 508 at any speed suitablefor entangling the target. In certain embodiments, the stabilized web210 is moved in the machine direction at a speed of at least about 10feet per minute (fpm), such as from about 50 fpm to about 250 fpm.

Upon completion of the entangling step, the fluid-permeable anchoringlayer is entangled about the layer of fibers, forming a layeredcomposite material of the present invention, in a manner as describedabove and as depicted in the examples shown in FIGS. 1 and 2.

FIG. 6 depicts hydroentanglement of a target web similar to thatdepicted in FIG. 5, except that the stream of fluid 508 is urged througha mask 600 that moves relative to the jet 530. The mask 508 may revolveabout a series of guides or rollers 660 in order to, at various pointsin time, align different portions of the mask 600 with the stream fluid508.

The mask 600 has a spatially-varying permeability to the stream of fluid508. In particular, as shown in FIG. 6 and FIG. 7 (a perspective view ofthe mask 600), the spatially varying permeability is created by aincluding a pattern of high permeability portions 620 and lowpermeability portions 630. The high permeability portions 620 may be,for example, open space (which permits essentially all of the fluid topass through the high permeability portion 620). Alternatively, highpermeability portions 620 may comprise a supporting screen, such asscreen 650 shown in FIG. 7 that is sufficient to provide mechanicalsupport to the mask 600, but does not impede a significant portion ofthe flow of the stream of fluid 508. In one embodiment, the highpermeability portions 620 have an open area of at least about 50percent, and more preferably at least about 65%.

By contrast, the low permeability portions 630 of the mask 600 typicallyblock most or preferably all of the stream of fluid 508 urged intocontact therewith from contacting the target web 550.

At a first instant in time, when the jet 530 is above a highpermeability portion 620 of the mask, a portion of the target web 550underneath the jet 530 is contacted with the stream of fluid 508 and isthereby entangled. In contrast, at a second instant in time, when thejet 530 is above a low permeability portion 630 of the mask, a portionof the target web 550 underneath the jet 530 is not contacted (or,alternatively, minimally contacted ) with the stream of fluid 508 and isthereby left relatively unentangled.

Over a time interval (i.e., a full pattern cycle) over which the mask isallowed to revolve completely around, the pattern of high permeabilityportions 620 and low permeability portions 630 on the mask 600 arethereby transferred to a length of the target web 550, forming apatterned, layered composite material. An example of a length 800 ofpatterned, layered composite material 810 is shown in FIG. 8. Theprocess then repeats, generating a series of identical lengths oflayered, composite material, which may later be separated from oneanother (e.g., by cutting).

Note that in FIG. 8, a pattern of unentangled raised flowers is shownagainst a uniform flat background. Note that if the low permeabilityportions 630 of the mask 800 are not completely open (e.g., comprise ascreen-as shown in FIG. 7), then some of the blocked portions of thescreen may be in effect “transferred” onto the layered compositematerial as a minority area of raised background features 850, e.g.,fine lines or cells; distributed in a majority portion 860 of entangledregions that provide tensile to the layered, composite material.

The length 800 of the layered, composite material over which the patternmay be repeated (i.e., the length of the mask if laid on a flat surface)is variable and may be, for example from about 50 cm to about 10 m. Notethat the boundaries of length 80 are shown in phantom in FIG. 8.

The mask 800 may be made by various methods known in the art. Forexample, mask 800 may be made by selectively etching a metal plate. Theplate may be formed of a flexible sheet of aluminum, stainless steel, orcopper, or from a polymeric material including plastic or rubber (whichmay be reinforced), and may have a thickness of, for example about 0.05mm to about 0.5 mm.

While FIGS. 6-8 depict one process for creating a visibly patterned,layered, composite material, other processes are contemplated. Forexample, rather than utilizing a mask that moves relative to the jets,the jets may be selectively blocked in certain locations, thus givingrise to lines or stripes of unentangled raised regions adjoining orinterspersed with entangled low regions.

In yet another embodiment of the invention, a visible pattern isprovided using a topographic forming surface. In this embodiment of theinvention a stream of fluid is urged into contact with a target web thatis supported on a topographic forming surface. The topographic supportmember generally includes an arrangement of peaks and valleys as well asan arrangement of apertures and may be similar to, for example, thetopographic support members disclosed in U.S Pat. Nos. 5,827,597 and5,674,587 (both to James et al.) which are hereby incorporated byreference in their entirety. The arrangement of peaks and valleys may beformed by any suitable techniques such as mechanical drilling, laserdrilling, laser ablation, raster scanning, laser modulation, among othertechniques.

In embodiments of the present inventive method, a layered structurecomprising a layer of fibers and a fluid permeable anchoring layer arepositioned on the topographic support member. Streams of fluid aredirected onto the layered structure thereby molding the layeredstructure to the topographic support member and entangling the layer offibers about the fluid permeable anchoring layer.

In one preferred embodiment as depicted in FIG. 9, fluid, permeableanchoring layer 900 is positioned in direct contact with the topographicsupport member 910 and layer of fibers 920 is positioned on the fluid,permeable anchoring layer. As such, the layer of fibers 920 at leastpartially shields the fluid permeable anchoring layer from the fluid.The layer of fibers 920 may include various materials such as thosedescribed above for the fibrous layer 122.

In a further preferred embodiment, the layer of fibers includescellulose such as wood pulp, preferably mercerized or crosslinked pulpas discussed above. In yet another preferred embodiment, the layer offibers 920 includes at least two distinct layers, such as a layer ofsynthetic fibers 930 positioned directly on the fluid, permeableanchoring layer 900 and a layer of cellulose fibers 940 (e.g. pulp)positioned directly on the layer of long fibers 930. In this embodiment,the stream of fluid 508 sequentially impacts the layer of cellulosefibers 940, the layer of long fibers 930, the fluid, permeable anchoringlayer 900, then the topographic support member 910. In this embodimentof the invention, the layer of synthetic fibers 930 and the fluid,permeable anchoring layer 900 act as barriers, preventing the relativelyshort cellulose fibers from being transported towards drainage apertures960 formed in the topographic support member 910. As a result there islittle chance of the short cellulose fibers clogging the drainageapertures 960, which would result in process difficulties.

EXAMPLES

The following Examples are illustrative of the present invention and arenot intended to be limiting in any manner.

Example 1

In each of the following examples, a target web was placed on a 80-meshmetal screen forming surface, on a rotating cylindrical drum. The targetweb consisted of a layer of fibrous material and a fluid-permeableanchoring layer. The fluid permeable anchoring layer used was a 12 gsmlayer of spun-bonded polypropylene, commercially available from BBAFiberweb. The fibrous material was a blend of 70% rayon fibers and 30%polyester fibers of varying basis weight. The drum was rotated to movethe layer of fibers at a linear speed of 100 fpm. The jets were orientedto expel a stream of pressurized water to strike the target webperpendicularly to the target web. The jets were arranged in a row ofjets spaced to a jet density of 30 jets/inch. All fibrous layers weresubject to an initial stabilization treatment in which water was urgedthough each of a number of 0.005-inch diameter jets at 600 psi toloosely bond the fibers prior to entangling with the spun-bondedpolypropylene. The drum was allowed to rotate completely 6 times, thusallowing a given point on the layer of fibers to pass through the row ofjets 6 times. The pressure of the water emanating from the jets wasvariable.

The lamination strength for each sample was measured using theLamination Strength Test performed as follows (to yield a LaminationStrength Value (LSV)):

A 1 in.×1 in. sample of the material (comprising an anchoring layer anda fibrous layer having fibers entangle about the anchoring layer) to bemeasured was cut. The sample was mounted flat, with double face adhesivetape (Scotch double-coated coated tape Model #666), on the surfaces oftwo stainless steel cubes (having surface dimensions of approximately 1in.×1 in.) and the sample is thus sandwiched between the two cube faces.The mounted sample is compressed between the cubes for at least 6seconds at 5 psi or more. Next the cubes are crosshead pulled apart at acrosshead speed of 2 inches/minute and the force over time is measuredusing an Instron force-measurement measurement gauge. The LaminationStrength Value is equal to the peak load (related to the first peak onthe Instron output graphics display) recorded for the sample.

The following drapeability test was performed on various fibrous,non-woven structures to determine the drapeability (basis weight/MCB)according to the present invention. Modified Circular Bend Stiffness(MCB) is determined by a test that is modeled after the ASTM D 4032-82CIRCULAR BEND PROCEDURE, the procedure being considerably modified andperformed as follows. The CIRCULAR BEND PROCEDURE is a simultaneousmulti-directional deformation of a material in which one face of aspecimen becomes concave and the other face becomes convex. The CIRCULARBEND PROCEDURE gives a force value related to flexural resistance,simultaneously averaging stiffness in all directions. The apparatusnecessary for the CIRCULAR BEND PROCEDURE is a modified Circular BendStiffness Tester, having the following parts:

1. A smooth-polished steel plate platform, which is 102.0 mm by 102.0 mmby 6.35 mm having an 18.75 mm diameter orifice. The lap edge of theorifice should be at a 45 degree angle to a depth of 4.75 mm;

2. A plunger having an overall length of 72.2 mm, a diameter of 6.25 mm,a ball nose having a radius of 2.97 mm and a needle-point extending 0.88mm therefrom having a 0.33 mm base diameter and a point having a radiusof less than 0.5 mm, the plunger being mounted concentric with theorifice and having equal clearance on all sides. Note that theneedle-point is merely to prevent lateral movement of the test specimenduring testing. Therefore, if the needle-point significantly adverselyaffects the test specimen (for example, punctures an inflatablestructure), than the needle-point should not be used. The bottom of theplunger should be set well above the top of the orifice plate. From thisposition, the downward stroke of the ball nose is to the exact bottom ofthe plate orifice;

3. A force-measurement gauge and more specifically an Instron invertedcompression load cell. The load cell has a load range of from about 0.0to about 2000.0 g;

4. An actuator and more specifically the Instron Model No. 1122 havingan inverted compression load cell. The Instron 1122 is made by theInstron Engineering Corporation, Canton, Mass.

In order to perform the procedure for this test, as explained below,three representative samples for each article are necessary. Thelocation of the non-woven structure to be tested is selected by theoperator. A 37.5 mm by 37.5 mm test specimen is cut from each of thethree samples at corresponding locations. Prior to cutting the samplesany release paper or packaging material is removed and any exposedadhesive, such as garment positioning adhesive, is covered with anon-tacky powder such as talc or the like. The talc should not affectthe BW and MCB measurements.

The test specimens should not be folded or bent by the test person, andthe handling of specimens must be kept to a minimum and to the edges toavoid affecting flexural-resistance properties.

The procedure for the CIRCULAR BEND PROCEDURE is as follows. Thespecimens are conditioned by leaving them in a room that is 21° C.,+/−1° C. and 50%, +/−2.0%, relative humidity for a period of two hours.The weight of each cut test specimen is measured in grams and divided bya factor of 0.0014. This is the basis weight in units of grams persquare meter (gsm). The values obtained for the basis weight for each ofthe samples is averaged to provide an average basis weight (BW). Thisaverage basis weight (BW) may then be utilized in the formulas set forthabove.

A test specimen is centered on the orifice platform below the plungersuch that the body facing layer of the test specimen is facing theplunger and the barrier layer of the specimen is facing the platform.The plunger speed is set at 50.0 cm per minute per full stroke length.The indicator zero is checked and adjusted, if necessary. The plunger isactuated. Touching the test specimen during the testing should beavoided. The maximum force reading to the nearest gram is recorded. Theabove steps are repeated until all of three test specimens have beentested. An average is then taken from the three test values recorded toprovide an average MCB stiffness. This average MCB value may then beused in the formulas set forth above. Drapeability is calculated asbasis weight divided by the average MCB value determined above.

The following density test was performed on various thin layers offibers and fibrous, non-woven structures to determine the thickness,according to the present invention.

Strips of material of 5 cm width are cut. To measure tensile strength inmachine direction, strips are oriented such that machine direction isoriented longitudinally. To measure tensile strength in cross-machinedirection, strips are oriented such that cross-machine direction isoriented longitudinally. The procedure was accomplished using an Emvecogauge using an applied pressure of 0.07 psi over a foot size of 2500mm². The digital readout is accurate to 0.0025 cm. An average of 5readings was recorded as the thickness. The foot of the gauge is raisedand the product sample is placed on the anvil such that the foot of thegauge is approximately centered on the location of interest on theproduct sample. When lowering the foot, care must be taken to preventthe foot from dropping onto the product sample or from undue force beingapplied. The foot was lowered at a rate of 0.1 inches/second. A load of0.07 p.s.i.g. is applied to the sample and the read out is allowed tostabilize for approximately 10 seconds. The thickness reading is thentaken. This procedure is repeated for at least three product samples andthe average thickness is then calculated. Density was then calculated bydividing mass of the sample by the volume (length times width timesaverage thickness, as determined above)

Example 1A

The spunbond material layer as placed “under” the fibrous layer (i.e.,the fibrous layer was positioned between the jets and thefluid-permeable anchoring layer). The jet pressure was 1500 psi. The webwas moved across the jets 4 times. The resulting layered, compositematerial had a lamination strength (LSV) of 25 grams (g.), a thicknessof 0.77 mm, a basis weight of 85 gsm, a density of 0.11 g/cc, and adrapeability of 7.9 gsm/g.

Example 1B

The spunbond material layer as placed under the fibrous layer. The jetpressure was 1500 psi. The web was moved across the jets 8 times. Theresulting layered, composite material had a lamination strength of 65grams (g.), a thickness of 0.73 mm, a basis weight of 88 gsm, a densityof 0.12 g/cc, and a drapeability of 8.6 gsm/g.

Example 1C

The spunbond material layer as placed on top of the fibrous layer. Thejet pressure was 1500 psi. The web was moved across the jets 4 times.The resulting layered, composite material had a lamination strength of32 grams (g.), a thickness of 0.90 mm, a basis weight of 90 gsm, adensity of 0.10 g/cc, and a drapeability of 9.1 gsm/g.

Example 1D

The spunbond material layer as placed on top of the fibrous layer. Thejet pressure was 1500 psi. The web was moved across the jets 8 times.The resulting layered, composite material had a lamination strength of106 grams (g.), a thickness of 0.85 mm, a basis weight of 83 gsm, adensity of 0.10 g/cc, and a drapeability of 11.8 gsm/g. Example 1E

The spunbond material layer as placed on bottom of the fibrous layer.The jet pressure was 2000 psi. The web was moved across the jets 4times. The resulting layered, composite material had a laminationstrength of 47 grams (g.), a thickness of 0.79 mm, a basis weight of 86gsm, a density of 0.11 g/cc, and a drapeability of 8.5 gsm/g.

Example 1F

The spunbond material layer as placed on bottom of the fibrous layer.The jet pressure was 2000 psi. The web was moved across the jets 8times. The resulting layered, composite material had a laminationstrength of 281 grams (g.), a thickness of 0.78 mm, a basis weight of 89gsm, a density of 0.12 g/cc, and a drapeability of 10.3 gsm/g. Example1G

The spunbond material layer as placed on top of the fibrous layer. Thejet pressure was 2000 psi. The web was moved across the jets 4 times.The resulting layered, composite material had a lamination strength of205 grams (g.), a thickness of 0.86 mm, a basis weight of 83 gsm, adensity of 0.10 g/cc, and a drapeability of 12.5 gsm/g. Example 1H

The spunbond material layer as placed on top of the fibrous layer. Thejet pressure was 2000 psi. The web was moved across the jets 8 times.The resulting layered, composite material had a lamination strength of341 grams (g.), a thickness of 0.92 mm, a basis weight of 83 gsm, adensity of 0.10 g/cc, and a drapeability of 11.8 gsm/g.

Example 2

In each of the following examples, a target web was placed on a 80-meshmetal screen forming surface, on a rotating cylindrical drum. The targetweb consisted of a layer of fibrous material between two separatefluid-permeable anchoring layers. The fluid permeable anchoring layerused was a 12 gsm layer of spun-bonded polypropylene, commerciallyavailable from BBA Fiberweb. The fibrous material was either a blend of70% rayon fibers and 30% polyester fibers of varying basis weight orpulp. The drum was rotated to move the layer of fibers at a linear speedof 100 fpm. The jets were oriented to expel a stream of pressurizedwater to strike the target web perpendicularly to the target web. Thejets were arranged in a row of spaced to a jet density of 30 jets/inch.Aside from the pulp layers, all fibrous layers of synthetic fiber weresubject to an initial stabilization treatment in which water was urgedthough each of a number of 0.005-inch diameter jets at 600 psi toloosely bond the fibers prior to entangling with the spun-bondedpolypropylene (and are referred to in Table 2 as “pre-bond”). The drumwas allowed to rotate completely a varying number of times. The pressureof the water emanating from the jets was variable.

Comparative Example 2A

The fibrous layer consisted of pulp. The jet pressure was 600 psi. Theweb was moved across the jets 4 times. The resulting layered, compositematerial had a lamination strength of 1 g. at the top interface (closestto the jets) and a lamination strength of 1 g. at the bottom interface(furthest from the jets), a thickness of 1.65 mm, a basis weight of 204gsm, a density of 0.124 g/cc, and a drapeability of 1.47 gsm/g.

Compartive Example 2B

The fibrous layer consisted of mercerized pulp. The jet pressure was 600psi. The web was moved across the jets 7 times. The resulting layered,composite material had a lamination strength of 2 g. at the topinterface (closest to the jets) and a lamination strength of 1 g. at thebottom interface (furthest from the jets), a thickness of 1.69 mm, abasis weight of 197 gsm, a density of 0.117 g/cc, and a drapeability of1.35 gsm/g.

Example 2C

The fibrous layer consisted of mercerized pulp. The jet pressure was1200 psi. The web was moved across the jets 4 times. The resultinglayered, composite material had a lamination strength of 41 g. at thetop interface (closest to the jets) and a lamination strength of 6 g. atthe bottom interface (furthest from the jets), a thickness of 1.42 mm, abasis weight of 195 gsm, a density of 0.137 g/cc, and a drapeability of1.40 gsm/g.

Example 2D

The fibrous layer consisted of mercerized pulp. The jet pressure was1200 psi. The web was moved across the jets 8 times. The resultinglayered, composite material had a lamination strength of 100 g. at thetop interface (closest to the jets) and a lamination strength of 31 g.at the bottom interface (furthest from the jets), a thickness of 1.58mm, a basis weight of 207 gsm, a density of 0.131 g/cc, and adrapeability of 1.25 gsm/g.

Example 2E

The fibrous layer consisted of mercerized pulp. The jet pressure was1200 psi. The web was moved across the jets 16 times. The resultinglayered, composite material had a lamination strength of 255 g. at thetop interface (closest to the jets) and a lamination strength of 109 g.at the bottom interface (furthest from the jets), a thickness of 1.32mm, a basis weight of 192 gsm, a density of 0.145 g/cc, and adrapeability of 1.39 gsm/g.

Example 2F

The fibrous layer consisted of the blend of synthetic fiber. The jetpressure was 1500 psi. The web was moved across the jets 4 times. Theresulting layered, composite material had a lamination strength of 23 g.at the top interface (closest to the jets) and a lamination strength of11 g. at the bottom interface (furthest from the jets), a thickness of0.95 mm, a basis weight of 98 gsm, a density of 0.103 g/cc, and adrapeability of 4.90 gsm/g.

Example 2G

The fibrous layer consisted of the blend of synthetic fiber. The jetpressure was 1500 psi. The web was moved across the jets 8 times. Theresulting layered, composite material had a lamination strength of 35 g.at the top interface (closest to the jets) and a lamination strength of24 g. at the bottom interface (furthest from the jets), a thickness of0.89 mm, a basis weight of 97 gsm, a density of 0.109 g/cc, and adrapeability of 5.39 gsm/g.

Example 3

In each of the following examples, samples were placed on atopographical forming surface (an acetal sleeve) having an arrangementof peaks and valleys in a “tricot” pattern, similar to those describedin U.S. Pat. No. 5,827,597, and also including a pattern of raisedflowers. The fluid permeable anchoring layer used was a 10 gsm layer ofspun-bonded fabric commercially available from BBA Fiberweb. The drumwas rotated to move the layer of fibers at a linear speed of 100 fpm.The jets were in oriented perpendicularly to the layer of fibers andarranged in a row of spaced to a jet density of 30 jets/inch. The drumwas allowed to rotate completely 6 times, thus allowing a given point onthe layer of fibers to pass through the row of jets 6 times.

Example 3A

The layer of fibers 920 was a pre-bonded layer of a blend of 30%polyester fibers and 70% rayon fibers having a total basis weight of 60gsm. The resulting layered, composite material had excellent laminationstrength and abrasion resistance and well-defined images.

Example 3B

The experiment in Example 2A was repeated except that a 90 gsm layer ofmercerized pulp (Porosanier, commercially available from RayonierCorporation) was placed on top of the layer of pre-bonded syntheticfibers. Lamination and image definition was excellent.

Table 1 shows materials made or tested in the above examples and thedensity, lamination strength, and drapeability associated therewith.Such values clearly illustrate the advantageous and surprisingly uniquecombination of high lamination strength and either or both of highdrapeability or low density associated with the materials of the presentinvention. It is also notable from Table 1 that by placing thefluid-permeable anchoring layer above the fibrous layer that laminationstrength is improved and drapeability remains high.

It is also notable that for otherwise similar process conditions,lamination strength is surprisingly greater between the fluid-permeableanchoring layer and the fibrous layer when the fluid-permeable anchoringlayer is oriented on top of the fibrous layer. These high laminationstrengths are possible without compromising drapeability or density.

Furthermore, Table 2 illustrates that it is surprisingly possible toform abrasion resistant “sandwich structure” materials thatsimultaneously have high drapeability, low density and are resistant todelamination. It is also surprisingly noted that it is possible for suchhigh lamination strength materials to be made at relatively low jetpressure, particularly for higher basis weights.

TABLE 1 Position of Lamination anchoring strength Thickness Basis WtDensity MCB Ex layer psi # passes (g.) (mm) (gsm) (g/cc) (g.)Drapeability 1A bottom 1500 4 25 0.77 85 0.11 11 7.9 1B bottom 1500 8 650.73 88 0.12 10 8.6 1C top 1500 4 32 0.90 90 0.10 10 9.1 1D top 1500 8106 0.85 83 0.10 7 11.8 1E bottom 2000 4 47 0.79 86 0.11 10 8.5 1Fbottom 2000 8 281 0.78 89 0.12 9 10.3 1G top 2000 4 205 0.86 83 0.10 712.5 1H top 2000 8 341 0.92 90 0.10 8 11.8

TABLE 2 Lamination Strng., g Thickness Basis Wt Density MCB Ex Core psi# passes Top Face Bottom mm gsm g/cm3 MCB, g Drapeability Comp 1 poropulp 600 4 1 1 1.65 204 0.124 139 1.47 Comp 2 poro pulp 600 7 2 1 1.69197 0.117 146 1.35 3 poro pulp 1200 4 41 6 1.42 195 0.137 139 1.40 4poro pulp 1200 8 100 31 1.58 207 0.131 165 1.25 5 poro pulp 1200 16 255109 1.32 192 0.145 138 1.39 7 poro pulp 1500 4 131 22 1.48 208 0.141 1301.60 8 pre-bond 1500 4 23 11 0.95 98 0.103 20 4.90 9 pre-bond 1500 8 3524 0.89 97 0.109 18 5.39

1. A layered, composite material comprising a fibrous, fluid-permeableanchoring layer and a fibrous layer comprising fibers entangled aboutsaid anchoring layer, said composite material having an LSV of greaterthan about 20 grams and a drapeability of greater than about 4 gsm/g. 2.The composite material of claim 1 wherein said material has an LSV ofgreater than about 50 grams.
 3. The composite material of claim 1wherein said material has an LSV of greater than about 100 grams.
 4. Thecomposite material of claim 1 wherein said material has a drapeabilityof greater than about 8 gsm/g.
 5. The composite material of claim 1wherein said material has a drapeability of greater than about 16 gsm/g.6. The composite material of claim 1 wherein said material has a densityof less than about 0.15 g/cc.
 7. The composite material of claim 1wherein said anchoring layer is selected from the group consisting ofspun-bonded material, through air-bonded material, and combinations oftwo or more thereof.
 8. The composite material of claim 7 wherein saidanchoring layer comprises a spun-bonded material comprising one or morepolyolefin fibers.
 9. The composite material of claim 1 wherein at leasta portion of the fibers of said fibrous layer having fibers entangledabout said anchoring layer comprise cellulose fibers.
 10. The compositematerial of claim 9 wherein said cellulose fibers comprise wood pulp.11. The composite material of claim 10 wherein said wood pulp comprisesmercerized pulp.
 12. The composite material of claim 10 wherein saidwood pulp comprises cross-linked pulp.
 13. The composite material ofclaim 1 comprising a cross-section of entangled region and across-section of unentangled region, said entangled and unentangledregions being visibly distinct from one another.
 14. The compositematerial of claim 1 comprising a continuous cross-section of entangledregion and a plurality of discrete cross-sections of unentangled regionspositioned substantially within said continuous cross-section ofentangled region.
 15. A layered, composite material comprising afibrous, fluid-permeable anchoring layer and a fibrous layer comprisingfibers entangled about said anchoring layer, said composite materialhaving an LSV of greater than about 20 grams and a density of less thanabout 0.15 g/cc.
 16. The composite material of claim 15 wherein saidmaterial has an LSV of greater than about 50 grams.
 17. The compositematerial of claim 15 wherein said material has an LSV of greater thanabout 100 grams.
 18. The composite material of claim 15 wherein saidmaterial has a density of less than about 0.12 g/cc.
 19. The compositematerial of claim 15 wherein said anchoring layer is selected from thegroup consisting of spun-bonded material, through air-bonded material,and combinations of two or more thereof.
 20. The composite material ofclaim 19 wherein said anchoring layer comprises a spun-bonded materialcomprising one or more polyolefin fibers.
 21. The composite material ofclaim 15 wherein at least a portion of the fibers of said fibrous layerhaving fibers entangled about said anchoring layer comprise cellulosefibers.
 22. The composite material of claim 21 wherein said cellulosefibers comprise wood pulp.
 23. The composite material of claim 22wherein said wood pulp comprises mercerized pulp.
 24. The compositematerial of claim 22 wherein said wood pulp comprises cross-linked pulp.25. The composite material of claim 15 comprising a cross-section ofentangled region and a cross-section of unentangled region, saidentangled and unentangled regions being visibly distinct from oneanother.
 26. The composite material of claim 15 comprising a continuouscross-section of entangled region and a plurality of discretecross-sections of unentangled regions positioned substantially withinsaid continuous cross-section of entangled region.
 27. A personal careproduct comprising a material of claim
 1. 28. The personal care productof claim 27 wherein said product comprises a sanitary pad or wipe. 29.The personal care product of claim 28 wherein said product is a sanitarypad comprising a topsheet comprising the material of claim
 1. 30. Thepersonal care product of claim 29 wherein said anchoring layer comprisesa body-faceable surface of said sanitary pad.
 31. A personal careproduct comprising a material of claim
 15. 32. The personal care productof claim 31 wherein said product comprises a sanitary pad or wipe. 33.The personal care product of claim 32 wherein said product is a sanitarypad comprising a topsheet comprising the material of claim
 1. 34. Thepersonal care product of claim 33 wherein said anchoring layer comprisesa body-faceable surface of said sanitary pad.